Dairy product that does not contain emulsification salts and process for making same

ABSTRACT

The present invention is directed to a process for making fat-containing dairy based food products such as cheese, without the use of emulsification salts and products made by the process.

FIELD OF THE INVENTION

[0001] This invention relates to dairy based food product, to a processfor making a dairy based food product, and to a product made by theprocess.

BACKGROUND

[0002] Many traditional dairy food products such as cheeses, yoghurtsand the like use enzymes and/or microorganisms in order to produceappropriately flavoured and textured end products. Generally, cheesesand related products made by traditional processes require a maturationor ripening time in order to allow such enzymes and/or microorganisms tofully develop the required flavour and texture. Due to the variety ofdifferent manufacturing processes currently used there is a generalinconsistency in the market place regarding the flavour and texture ofdairy products, and cheeses in particular, which are being sold underthe same product name, for example, cheddar cheese, edam cheese, and thelike.

[0003] In addition, as these traditionally made dairy products maycontain residual enzymes or active microorganisms they have a limitedshelf life and can spoil easily especially if stored under conditionssuch as elevated temperatures.

[0004] This problem is overcome in processed cheese manufacture, aprocess which generally involves grinding and cooking the traditionalcheese with an emulsifying salt to form a homogeneous molten mass whichcongeals on cooling into a finished cheese-like product of low enzymeand microorganism activity and therefore consistent, uniform texture,stable flavour, and improved shelf life over time compared withtraditionally made cheeses. As processed cheese involves furtherprocessing of traditional cheese, processed cheese is more expensive toproduce. Processed cheeses also tend to be produced with a limited rangeof textures which are not comparable to the type and range of texturesavailable for traditionally made cheeses. In addition, processed cheeseproducts created are bland in flavour, and contain emulsifying salts. Asa result of the addition of emulsifying salts these products can nolonger be described as “natural” cheeses.

[0005] A process is described in U.S. Pat. No. 6,183,805 for preparing aprocessed cheese product which does not use a traditionally made cheeseand aims to produce processed cheese from milk in a short period oftime. Such a simplified process involves the direct conversion of milkwithout fermentation, enzymatic treatment and/or intermediate steps offorming and separating curds and whey. In this process, pasteurised milkis acidified and subjected to UF to form a UF retentate. The UFretentate is evaporated to form a pre-cheese. The pre-cheese is thencooked with emulsifying salts to form a processed cheese product whichis ready for immediately packaging and which has similar organolepticproperties to processed cheeses made by cooking traditional cheeses.

[0006] A process is described in U.S. Pat. No. 4,497,834 for preparing aprocessed cheese product by direct conversion of milk as above wherebymilk is first condensed to the approximate proportions of total solidsand moisture corresponding to that desired in the final product, lactoseconcentration in the milk is reduced and flavours and other additivesincorporated into the condensed milk before the mixture is gelled byheating. The gelled composition may then be packaged and cooled. The useof emulsifying salts is taught for fat containing cheeses to provideuniform distribution of the fat and to ensure against fat separation.However, a product made by the process of this patent, as disclosed inU.S. Pat. No. 6,183,805, resulted in a doughy product with essentiallyno cheese or cheese-like structure, essentially no cheese flavour andwhich, upon melting exhibited unstable emulsions with severe oil-off anda mealy grainy texture. Such products were found to be not acceptable bythe inventors of U.S. Pat. No. 6,183,805.

[0007] U.S. Pat. No. 6,183,804 describes a further method of producingprocessed cheese by the direct conversion of milk by first providing apowdered milk protein concentrate, reconstituting the powder, subjectingto fat and pH adjustment and cooking with emulsifying salts to produce aprocessed cheese product. This process is rapid and efficient, lesslabour intensive and less costly than traditional cheese making methods.However, as discussed above, the use of emulsifying salts limits thetype of cheese able to be made by such a process and would preclude suchcheeses from generally being considered as “natural” cheeses.

[0008] It would be desirable to provide a rapid manufacturing processfor making a fat-containing stable dairy based food product, and inparticular a “natural” cheese product, which does not include the use ofemulsifying salts or non dairy derived emulsifying agents, and whichprovides a consistent storage stable product for immediate distributionto the market place.

[0009] U.S. Pat. No. 6,177,118 describes a rapid process for making both“natural” and processed cheeses by direct conversion of milk withoutfermentation or coagulation. This process involves a combination of milkretentate with a dry protein concentrate or isolate. This mixture isheated to 80° C. for two minutes to form a homogenous molten plasticmass which may be packaged immediately and cooled to solidify the cheeseproduct. No emulsifying salts are used in this process and fat is heldin solution by simple blending shortly before the high heat melt. Theproduction of the high heat melt makes this process similar to a processfor making processed cheese so that only “natural” cheese productshaving a limited range of textures are likely to be produced by such aprocess. This “natural” cheese can be used as a base to make a processedcheese by melting, combining with emulsifying salts and heating to 80°C. for two minutes to produce a further homogenous plastic mass, whichmay be packaged directly and cooled to form a solid processed cheesemass. In addition, U.S. Pat. No. 6,177,118 teaches the addition ofstarter culture in the process of “natural” cheese production, however,under conditions which do not allow fermentation per se to take place.Such a process further necessitates the use of a subsequent heattreatment step to stop microbial growth to achieve a cheese producthaving an improved stability and longer shelf life than conventionallymade cheese products.

[0010] U.S. Pat. No. 5,213,827 discloses a process of producing aprecheese or a “natural” cheese. This is implemented by first producinga skim milk retentate, fermenting the retentate and centrifuging toproduce a concentration to which additives such as fat, salt, protein,etc may be added before re-fermenting to produce a cheese base. Thecheese base may be further processed by fermentation to produce aprecheese suitable for use in the manufacture of processed cheese. Thisprecheese may be texturised to produce a “natural” cheese. However, sucha “natural” cheese may still be unstable in storage due to the presenceof fermenting bacteria.

[0011] U.S. Pat. No. 4,205,090 discloses a method of making a “natural”cheese again by first producing a skim milk retentate by ultrafiltrationto incorporate whey protein into cheese. Such a UF retentate may then beconverted immediately to cheese using the traditional method of additionof starter culture and/or rennet to initiate coagulation. The presenceof residual microorganisms and/or enzymes makes the resulting “natural”cheese unstable in storage.

[0012] Other workers have used direct acidification processes tomanufacture cheeses without the need to use microorganisms. For example,GDL may be used in combination with or in the place of starter cultures.GDL addition to milk or UF retentates reduces pH and results in curdformation which may be directly packaged and marketed. However suchprocesses are generally only used in the production of soft cheeses suchas cottage cheese and feta. An overview of the use of GDL is given inEuropean Dairy Magazine No 2 (1989), p61-66.

[0013] It would be desirable to provide a rapid process of making abroad range fat-containing stable dairy based food products, andparticularly a “natural” cheese product, which does not include theaddition of starter culture so that endogenous microbial growth in thefinal product is not a concern, wherein the final product has aconsistent flavour and texture from the time of manufacture, an improvedstability and longer shelf life than conventionally made dairy products.

[0014] It is an object of the present invention to provide suchprocesses and/or at least to provide the public with a useful choice.

SUMMARY OF THE INVENTION

[0015] The present invention provides a process for producing afat-containing dairy based food product whereby a first milk proteinbased composition is dehydrated to increase total solids and combinedwith at least one additive preferably selected from the group comprisingbut not limited to a flavour enhancer, a texture enhancer, a nutritionalsupplement, a fat source, a carbohydrate source, condiments, a secondmilk protein based composition, a non-dairy protein source or any otherdairy derived product or GRAS ingredient, to create a stable emulsionwithout the use of an emulsifying salt or non dairy derived emulsifyingagents. This emulsion is heated to at least 50° C. for up to 60 minutesto initiate coagulation to form a gel and preferably cooled to less than20° C. to complete gel formation to give a final product. The conditionsof coagulation and gel formation of the present invention are not assevere as the prior art processes which produce an untexturised melt. Ingeneral, at least the first milk protein based composition is modifiedto give the required nutritional composition, texture, functional and/orflavour characteristics of the final food product in particular, suchmodifications are selected to at least enhance hydrophobicity in orderto ensure an acceptable level of fat emulsification. In addition, themodifications, including the temperature, time, shear and pressureconditions used in the present process are selected not only to causesufficient coagulation, but also to produce a broad range of desiredtexture characteristics in the gelled end product rather than producinga limited texturised product as are generally produced by standardcheese making processes.

[0016] Such modifications include lactose adjustment, pH adjustment,mineral level adjustment (e.g. calcium depletion), salt adjustment, wheyprotein adjustment, enzyme addition (to improve flavour and/or texture),moisture adjustment. (i.e. fat/water addition), temperature treatments,ultrasonication, shearing processes or combinations thereof. Suchmodifications may be carried out in the staring composition, i.e. beforedehydration, or after dehydration or at any other suitable step in theprocess so that the present process has increased flexibility over priorart processes.

[0017] Preferably, the process comprises the combination of a first andsecond milk protein based composition, wherein at least one of saidcompositions has been modified as described above.

[0018] The process may be a batch, semi-continuous or continuousprocess. Preferably the process is a semi-continuous process and mostpreferably, the process is a continuous process.

[0019] The term “milk protein based composition” as used herein refersto milks or milk products containing milk proteins. Included in thisterm are skim milk whole milk, reduced fat milk, fat enhanced milk, milkultrafiltration retentates, milk concentrates, milk powders, and milkpowders reconstituted to form a solution, as well as milk productsderived from these.

[0020] The milks or milk products may be sourced from any milk producinganimal or from an analogue milk.

[0021] Stable dairy based food products created by this technology mayamongst others comprise: hard, soft or semi-soft cheese, cream cheese,yoghurt, mousse, dessert, dairy dips, dressing, or dairy additive foruse as a food ingredient. Depending on the desired product, thecomposition, flavour and texture is controlled by modifying theingredient materials and/or proportions used when implementing thisprocess.

[0022] The present invention will now be described with reference to theaccompanying drawings in which:

[0023]FIG. 1 shows: a flow diagram of a first process embodiment of thepresent invention;

[0024]FIG. 2 shows: a flow diagram of a second process embodiment of thepresent invention; and

[0025]FIG. 3 shows: a flow diagram of a third process embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

[0026] The present invention is directed to a process for producing afat-containing stable dairy based food, particularly a “natural” cheeseproduct, having flavour and texture characteristics of a conventionallyproduced product but having the additional benefits of long shelf life,rapid manufacture and market release, and flexible functionality. Inparticular, the present process produces a fat-containing dairy productwithout the need for the addition of emulsifying salts or non dairyderived emulsifying agents, as well as providing, an improved consumerproduct performance by avoiding the use of live microorganisms or therequirement for the action of enzymes, thereby increasing the shelf lifeof the final product

[0027] The process broadly comprises a combination of at least one dairybased protein composition feed stream with any one of a number of GRASingredients (but excluding the group known as emulsifiers), including asecond dairy based protein composition feed stream, which under suitableprocessing conditions form a stable emulsion. The emulsion is heatedeither during its formation or subsequent thereto, where upon itcoagulates to form the desired gelled dairy product. The protein feedstream(s) may be modified in a variety of ways at a variety of steps tomodify the desired properties of the final food product, includingtexture, flavour, functionality and nutritional composition. The gelstrength of the final food product is controlled depending on the typeof end product desired. Typical end products include hard cheese, softcheese, cheese paste, yoghurt, dairy dips, mousse, salad dressings etc.Thus the present invention provides a process capable of producing abroad range of products.

[0028] In particular, the present invention provides a process formaking a fat-containing stable dairy based food product comprising thesteps:

[0029] (i) providing a first milk protein based composition;

[0030] (ii) optionally dehydrating said first milk protein basedcomposition to increase total solids to 15 to 98 wt % if required,preferably 15 to 60% for fluid compositions, 50 to 75% for paste-likecompositions, or 90 to 99% for powder compositions;

[0031] (iii) combining the product from steps (i) or (ii) with at leastone additive, other than an emulsifying salt or non dairy derivedemulsifying agents, selected from the group comprising but not limitedto a flavour enhancer, a texture enhancer, a nutritional supplement, afat source, a carbohydrate source, condiments, a second milk proteinbased composition, a non-dairy protein source, or any other dairyderived product or GRAS ingredient and agitating to create a stableemulsion;

[0032] (iv) heating the emulsion of step (iii) to a temperature above50° C. for up to 60 minutes, preferably for up to 10 minutes, toinitiate coagulation and gel formation;

[0033] (v) optionally further additional agitating either concurrentlywith the preceding heating step (iv) or subsequent thereto, to assist incoagulation and to impart the desired texture modification;

[0034] (vi) optionally forming the mixture of step (iv) or (v) into asuitable shape; and

[0035] (vii) cooling the mixture of step (iv) or (v), or the formedmixture of step (vi), preferably to a temperature of less than 20° C.,to complete gel formation and to produce a final food product; whereinthe first and/or second milk protein based composition is modified atone or more steps of the process; wherein the first and/or second milkprotein based composition is modified to alter one or more propertiesselected from flavour, texture, nutritional composition andfunctionality of the final food product; and wherein said first and/orsecond milk protein based composition comprises a milk or milk productselected from the group consisting of pasteurised or unpasteurised wholemilk, skim milk, reduced fat milk, fat enhanced milk, milkultrafiltration retentates, milk concentrates, powered whole, reducedfat or skim milk, reconstituted whole, reduced fat or skim milk powderor any combination therefor, wherein said milk or milk product issourced from any milk producing animal or analogue milk; with theproviso that when the first milk protein based composition of step (i)or (ii) is a milk ultrafiltration retentate, the second milk proteinbased composition or non-dairy protein source added in step (iii) is nota protein concentrate or isolate when the process is used to makecheese.

[0036] The process of the present invention may further comprise thefollowing optional steps:

[0037] (viii) moulding/forming the cooled or partially cooled foodproduct into a suitable shape; and/or

[0038] (ix) packing the final food product into a suitable package.

[0039] The final food product may also be stored by refrigerating,chilling or freezing.

[0040] In a preferred embodiment, the agitating step (v) is included inthe process and is carried out during the heating step (iv). Morepreferably, the combining, heating and agitating steps ((iii)-(v)) arecarried out in a single apparatus whereby the formation of the emulsion,the coagulation and gelling occur concurrently or consecutively toimpart product texture.

[0041] These process steps are shown in schematic form in FIGS. 1, 2 and3. FIG. 1 shows a process comprising a single milk protein basedcomposition stream; FIG. 2 shows a process comprising an optional secondmilk protein stream and FIG. 3 shows a process comprising two milkprotein streams.

[0042] For some embodiments based on FIGS. 1, 2 and 3, the dehydrationstep (ii) may not be essential. For example, it will be appreciated thatwhere the starting material is a powdered milk, or the final product isof low total solids, dehydration may not be required.

[0043] Modifications

[0044] The various modifications are listed and the dotted lines inFIGS. 1-3 show the optional steps where such modifications may occur.The modifications are to facilitate the desired texture, flavour,nutritional composition or other properties, such as functionalproperties, of the final food product Such modifications may include oneor more of the following:

[0045] pH Adjustment

[0046] This may be achieved by addition of an acidulant or alkali.Preferably the adjustment would be achieved by addition of a suitablefood grade acid or lactone. The acid or lactone would be diluted withwater to less than 5% w/w before addition and the addition would beconcurrent with suitable agitation of the milk protein based compositionto ensure adequate dispersion of the acidulant so as to avoidsignificant localized, uneven change in pH.

[0047] The pH adjustment may support a contribution to the desiredflavour of the final food product and may cause a modification in theproperties of the proteins in the milk protein based composition,thereby imparting a change to the contribution of these proteins tocoagulation processes, and texturisation processes and therefore thetexture of the final product

[0048] Mineral Level Adjustment (e.g. Calcium Depletion)

[0049] Mineral level adjustment may be achieved by methods comprisingaddition of specific required minerals, or removal by suitabletechniques. Some methods that may be used for removal include filtrationprocesses such as ultrafiltration (UF), diafiltration (DF), loosereverse osmosis (LRO) (otherwise known as nanofiltration), acid UF, andacid DF, using suitable membrane molecular weight (MW) cut offs for anyof the filtration techniques, ion exchange, a suitable pH, and otherconditions known in the art In particular, UF and DF methods asdescribed below under “step (ii)”, may be used.

[0050] The adjustment of specific mineral levels such as calcium levelmay support a contribution to the desired flavour of the final foodproduct and may cause a modification in the properties of the proteinsin the milk protein based composition, thereby imparting a change to thecontribution of these proteins to coagulation processes, andtexturisation processes and therefore the texture of the final product,as well as contributing to the required nutritional composition of thefinal food products.

[0051] Protein Adjustment (e.g. to Increase or Decrease Amount)

[0052] The protein content of the first milk protein based compositionof step (i) may be reduced by the addition of a milk permeate.Alternatively, the protein content may be increased by adding a sourceof milk-protein such as WPC, WPI, MPC, MPI, TMP, whey protein fractions,or any non-milk protein such as soya protein. Optionally, this additionwould be of an ultrafiltration retentate of increased protein to solidsratio as compared to milk, or by addition of powdered form of theprotein with sufficient time for hydration. Alternatively oradditionally, proteins may be added at any other suitable step in theprocess to give a desired protein content, nutritional value, orfunction in the final food product.

[0053] Fat Adjustment (e.g. to Increase or Decrease Amount)

[0054] The fat content of the first milk protein based composition ofstep (i) may be adjusted by separation of the milk protein basedcomposition, and standardisation of the fat content by the addition of acream. Alternatively, the fat content may be increased by adding asuitable source of fat such as cream, double cream, butter, anhydrousmilk fat (AMF), liquefied fresh frozen milk fat for recombining (FFMR),or a non-dairy fat such as vegetable oil. Alternatively or additionally,fat may be added at any other suitable step in the process to give adesired fat content in the final food product. Preferably, fresh doublecream is added before dehydration has been implemented by evaporationand/or drying, and/or at the combining step.

[0055] Salt Adjustment (e.g. Addition of NaCl, KCl)

[0056] Salt adjustment may be achieved by methods comprising addition ofspecific required salt compounds such as NaCl and KCl at one or moresteps of the process.

[0057] The salt adjustment may support a contribution to the desiredflavour of the final food product and may cause a modification in theproperties of the proteins in the milk protein based composition,thereby imparting a change to the contribution of these proteins tocoagulation processes, and texturisation processes and therefore thetexture of the final product, as well as contributing to the requirednutritional composition of the final food products

[0058] Lactose Adjustment (e.g. Removal to Achieve <10 wt % Preferably<6 wt % of final product)

[0059] Lactose adjustment may be achieved by methods comprising additionof a milk permeate, by addition of a dry lactose powder or lactosecontaining powder, or removal methods. Some of the methods that may beused for removal include filtration processes such as UF, DF, reverseosmosis (RO), LRO and microfiltration (MF). In particular, UF and DFmethods as described below under “step (ii)”, may be used. The primarypurpose of lactose adjustment may be to facilitate the desired texture,flavour and nutritional composition in the final food product.

[0060] Enzyme Addition (e.g. for Texture or Flavour Development)

[0061] Enzymes such as Rennet are traditionally used in cheese makingprocesses to assist in the traditional coagulation process step. In thepresent process, Rennet, or any other suitable enzymes known in the artmay be added at any one of several steps of the proposed process. Thepurpose of the addition is to support a contribution to the desiredflavour of the final food product and may cause a modification in theproperties of the proteins in the milk protein based composition,thereby imparting a change to the contribution of these proteins tocoagulation processes, and texturisation processes and therefore thetexture of the final product.

[0062] Moisture Content Adjustment (e.g. Addition of Water/Fat/Protein)

[0063] Moisture content may be adjusted upwards by addition of water ormay be adjusted downwards by addition of a lower moisture product thanthe milk protein based composition. Likely compositions that may beadded are fat and protein streams.

[0064] The purpose of the adjustment of moisture content would be tocontribute to the nutritional composition and texture of the final foodproduct.

[0065] Temperature Treatments

[0066] Temperature treatments may be executed by exposure of the milkprotein based composition to appropriate combinations of temperature andtime. These treatments may alter the characteristics of the proteins,and impart different flavours. The purpose of the temperature treatmentswould support a contribution to the desired flavour of the final foodproduct and may cause a modification in the properties of the proteinsin the milk protein based composition, thereby imparting a change to thecontribution of these proteins to coagulation processes, andtexturisation processes and therefore the texture of the final product.

[0067] Shearing/Texturisation Processes

[0068] Shearing/texturisation processes may modify the state of proteinand fat components in the milk protein based composition. Such amodification may be undertaken by a device such as a high shear mixer,high shear pump, homogenizer, extruder or any other suitable deviceknown in the art

[0069] Texturisation of the milk protein based composition may impartthe desired texture and/or functionality of the final food product.

[0070] The modifications may be carried out by any other suitabletechnique known in the art.

[0071] Step (i)

[0072] The first milk protein based composition of FIGS. 1-3 maycomprise a milk or milk product selected from pasteurised orunpasteurised whole milk, skim milk, reduced fat milk, fat enhancedmilk, milk ultrafiltration retentates, milk concentrates, powderedwhole, reduced fat or skim milk, reconstituted whole, reduced fat orslim milk powder or any combination thereof. Such milk may be sourcedfrom any milk producing animal or any analogue milk source. The secondmilk protein based composition of FIGS. 2 and 3 may comprise one or moreof the milk and milk products listed above for the first milk proteinbased composition.

[0073] The first and/or second milk protein based compositions aremodified in at least one step of the process by pH adjustment, minerallevel adjustment (e.g. calcium depletion), whey protein adjustment,lactose adjustment, adding NaCl/KCl, fat, water or enzymes, temperaturetreatments, or shearing processes as described above to give therequired nutritional composition, texture, functionality and/or flavourcharacteristics of the final food product using standard techniques inthe art. Where the second milk protein based composition comprises morethan one milk or milk product source, either or both of the milk or milkproduct source may be separately modified.

[0074] The fat and protein content of the first and/or second milkprotein compositions are adjusted to provide a fat content of between0.05 and 7%, preferably between 0.05 and 5%, and a protein content ofbetween 2 and 6%, preferably between 2.5 and 4% as described above under“modifications”.

[0075] Preferably, the process comprises the use of two milk proteinbased compositions where one or both streams have been modified, forexample as shown in FIGS. 2 and 3. The use of two milk protein basedcompositions allows greater flexibility to achieve desired properties ofthe final food product, including texture, flavour, functionality andnutritional composition.

[0076] Step (ii)

[0077] The first milk protein based composition may be dehydrated instep (ii) if required, by any suitable method known in the art such as,for example, by precipitation and separation, filtration, evaporation,and/or drying using conditions known in the art to form a composition inthe form of a liquid, paste or solid.

[0078] Precipitation and separation may be carried out using an optionalcoagulating substance treatment, followed by acidification, heating andconcentration of the total solids. In a preferred embodiment,pasteurised skim milk would be cooled to below a temperature which wouldpermit rapid coagulation. A coagulating substance, which would normallybe rennet, would be added. If this agent is rennet, it would be added ata rate of 0.001% to 0.01% v/v, and the skim milk then held for at leastfour hours. Precipitation is initiated by ‘in line’ injection of asuitable food grade acid or lactone to adjust the pH to within the rangeof 5.2 to 6.0. The introduced substance is thoroughly mixed with themilk flow using for example in line static mixers. The skim milk is thenheated either by direct or indirect heating to between 40 and 55° C. andheld for up to 5 minutes. The precipitated curd is captured on a screenand then washed in warm, acidified water. The curd/water mixture is thendewatered in a suitable device, preferably a decanter type device, andthe curd is optionally reduced in size by some suitable milling device.The curd is optionally dried using an appropriate method such as‘fluidised bed’ or ‘ring’ drying to a target moisture content of 4 to8%. This process concentrates the total protein content and alters themoisture, lactose, mineral and whey protein content, and the pH of themilk protein based composition.

[0079] Filtration may be carried out by UF, DF, RO, LRO (otherwise knownas nanofiltration), MF, acid UF and acid DF using suitable membrane MWcut offs for any of the filtration techniques, a suitable pH, and otherconditions known in the art. For the case of UF and/or DF, themilk-protein based composition may be optionally pasteurised, and in thecase of processing of whole milk would be standardised to a suitable fatlevel. The ‘milk’ temperature would be adjusted to the required membranefiltration feed temperature which may range from 0 to 60° C. but wouldbe preferably in the ranges of 5 to 15° C. or 45 to 55° C. The milkwould then be concentrated by continuous or batch ultrafiltration usinga suitable plant design and membranes of suitable MW cut off selectionsknown in the art, to yield a retentate stream with a milk protein levelof 50 to 90% protein in solids non fat, preferably 70 to 85%.Diafiltration would be used as required to achieve the target protein insolids non fat ratio. This may be either through continuous addition ofwater to one or more stages of the UF plant in the case of batch orcontinuous process or by batch addition at one or more-times into theretentate in the case of a batch UF process. This diafiltration waterwould be at a suitable temperature for the process being employed. TheUF and/or DF process may be conducted at a lowered milk pH in the rangeof 5.4 to 6.8 but preferably a pH in the range of 5.7 to 6.1, by theaddition of a dilute acid to the milk or diafiltration water. The acidused would preferably be a food grade acid such as lactic or citric aciddiluted to less than 5% w/w before addition, and the milk wouldpreferably be at less than 10° C. and preferably less than 5° C. Theresultant acidified retentate may be optionally pH adjusted with anappropriate alkali agent to a pH of 6 to 6.8%, preferably with diluteNaOH. A UF/DF process may obtain a yield of up to 60% total solids forwholemilk, and 40% total solids for skim milk, and preferably up to 45%for whole milk and 28% for skim milk.

[0080] The above process concentrates the total protein and fat contentand alters the moisture, lactose, and mineral content, and optionallythe pH of the milk protein based composition.

[0081] Evaporation may be carried out by techniques known in the artsuch as falling film, rising film, flash or agitated thin filmevaporation to give up to 75% total solids, preferably up to 65% totalsolids. Optionally a ‘fat’ stream may be added prior to the use of anyof these techniques to enhance concentrate flow properties and tocontribute to a desired fat content in the final food product.Preferably, fresh cream of 35 to 80% fat, most preferably approximately75% fat, is added, and preferably the fat content of the milk-proteinbased composition passing through evaporation does not exceed 55% fat inthe dry matter. Preferably the product temperature within the evaporatorshould not exceed 65° C. at any time, more preferably 60° C.

[0082] Further dehydration may also be carried out by techniques knownin the drying art such as roller, spray, ring or freeze drying to giveup to 99% total solids (w/w). Optionally a ‘fat’ stream may be addedprior to the use any of these techniques to contribute to a desired fatcontent in the final food product. Preferably, fresh cream of 35 to 80%fat, most preferably approximately 75% fat, is added, and preferably thefat content of the milk-protein based composition passing throughdehydration does not exceed 55% fat in the dry matter. Preferably theproduct temperature should not exceed 70° C.

[0083] When both a first and second milk protein based composition isused in the present process, either or both compositions may bedehydrated if necessary as described above.

[0084] Step (iii)

[0085] Preferably combining step (iii) may be carried out in a devicecapable of sufficient agitation of sufficient mechanical shear so as toproduce a homogeneous emulsion on mixing without having to addemulsifying salts. Examples of such suitable devices include anextruder, an auger device, an in-line static mixer, a Blentech™ twinscrew lay down cooker, a Stephan™ type cooker, a Rototherm™ evaporatorand any other suitable apparatus known in the art. Preferably thevarious streams would be added into the combining device such that anyfat stream to be added is put in first and liquefied if required,followed by any water required to provide a desired composition andtexture in the final product, followed by any high concentrationmilk-protein based compositions, followed by any other liquid or pastecomponents such as flavours, followed by any powdered components,followed by any acid. It is important that powders are added slowly toensure successful hydration. After all ingredients are added, it ispreferable that mixing is continued for a period of 5 to 30 minutes,most preferably 10 to 20 minutes, to ensure proper hydration of allingredients, and to ensure a homogeneous mixture, and to ensuresufficient emulsification of components.

[0086] The emulsion produced at step (iii) is stable in that fat remainsemulsified prior to and during subsequent process steps. In particular,the emulsion is formed as a result of at least one of the milk proteinbased compositions used in the process having been modified to enhanceits hydrophobicity.

[0087] A number of GRAS ingredients and other additives may be added atcombining step (iii) including water, flavours, texturisers, nutritionalsupplements, acids, additional protein sources etc.

[0088] A flavour enhancer which may be added at combining step (iii) ispreferably selected from one or more of the group consisting of NaCl,KCl, food grade acids (such as lactic acid, citric acid, acetic acid andthe like), lactose, fat, and flavours including enzyme modified cheeses.

[0089] A texture enhancer which may be added at step (iii) is preferablyselected from one or more of the group consisting of water, food gradeacid, lactose, fats, gums, starches, carbohydrates, sources ofmonovalent and divalent cations such as CaCl₂, NaCl and KCl.

[0090] pH modification may be effected at step (iii) by addition ofacidulants such as food grade acids and/or lactones. Preferably, thisaddition is after all other ingredients have been added.

[0091] A nutritional supplement which may be added at step (iii) ispreferably selected from one or more of the group consisting ofvitamins, minerals, carbohydrates, pre-biotics, and biologically activeagents.

[0092] A condiment which may be added at step (iii) is preferablyselected from one or more of the group comprising flavouring salts,spices, herbs, diced fruit and vegetables and the like.

[0093] The non-dairy protein which may be added at step (iii) may beselected from one or more of the group comprising soya protein, wheatprotein or any other suitable non-milk derived protein source. When theprocess is used for cheese making, in a further embodiment of theinvention, the non-dairy protein is not a protein concentrate or isolatewhen the first milk based protein composition is a UF retentate.

[0094] The second milk protein based composition which may be added atstep (iii) may comprise one or more of the group comprising a milk ormilk product selected from pasteurised or unpasteurised whole milk, skimmilk, reduced fat milk, fat enhanced milk, milk ultrafiltrationretentates, milk concentrates, powdered whole, reduced fat or skim milk,reconstituted whole, reduced fat or skim milk powder or any combinationthereof. Such milk may be sourced from any milk producing animal or anyanalogue milk source.

[0095] Preferably, the second milk protein based composition is selectedfrom the group comprising:

[0096] (a) whole milk, reduced fat milk, skim milk or reconstitutedwhole milk, reduced fat milk or skim milk having 0.05 to 7 wt % fat,preferably 0.05 to 5 wt % fat and 2 to 6 wt % protein, preferably 2.5 to4 wt % protein; and/or

[0097] (b) a milk of group (a) which has been dehydrated to increasetotal solids to 15 to 98 wt %; and/or

[0098] (c) a milk of group (a) and/or group (b) which has been modifiedto produce a desired property in the final food product.

[0099] When the process is used for cheese making, the second milkprotein based composition is not a milk protein concentrate or isolatewhen the first milk protein based composition is UF retentate.

[0100] It will be appreciated that any number of other additivescommonly used in food production may be added in this process such ascolourants, flavours and the like.

[0101] Step (iv)

[0102] The heating step (iv) may be carried out in a suitable device bydirect or indirect methods including steam injection, microwave energy,indirect steam or other heating fluids, indirect electrical heating,radio frequency, ohmic heating and the like to a suitable temperatureabove 50° C. In one embodiment heating is preferably carried out in thesame device as the combining and emulsification step (iii). The heatingstep preferably takes place whilst the emulsion is being continuouslymixed, preferably to a temperature range of between 50 to 120° C., morepreferably 60 to 90° C. and most preferably 65 to 75° C., for a periodof up to 60 minutes, preferably less than 10 minutes, more preferablyless than 5 minutes, to initiate coagulation and gel formation. Thetiming will vary depending on the properties and composition of theingredients used and on the properties of the particular final productbeing made. Where there has been an enzyme addition in any one of theprevious steps, the heating step would result in considerabledeactivation of the enzyme so that there would be greatly reducedresidual activity in the final product, and preferably no residualactivity. In addition, this step would also greatly reduce endogenousmicroorganism activity.

[0103] Coagulation is observed when the mixture begins to change from apaste-like appearance to a coherent gel. As discussed above, this stepis carried out under conditions which give rise to the development of abroad range of desired textures in the resulting gelled product, whilstavoiding the production of molten mass of limited textures as isproduced in standard processed cheese production.

[0104] Step (v)

[0105] Preferably the further agitation step (v) may be carried out in adevice capable of sufficient mechanical shear so as to produce thedesired texture in the final gelled product. Examples of such suitabledevices include an extruder, an auger device, a Blentech™ twin screw laydown cooker, Damrow single screw lay down cooker, a Rototherm™evaporator and any other suitable apparatus known in the art.

[0106] Preferably the further agitating step (v) takes placeconcurrently with heating step (iv), or subsequent thereto andpreferably in the same device. Most preferably steps (iii)-(v) takeplace concurrently in the same device.

[0107] Step (vi)

[0108] The forming step (vi) is optional and may be carried out by anysuitable method known in the art, for example, that the gelling mixtureof step (iv) may be formed into a suitable shape mechanically by usingad extruder or any other apparatus know in the art, or manually forsmaller batches. In addition, the forming step may be carried out beforeor after partial cooling of the gelling mixture.

[0109] Step (vii)

[0110] The cooling step (vii) may be carried out by any suitabletechnique known in the art. These techniques may include chilled waterbath, scraped surface coolers, cold belt, cold table, cold rollers, coldmoulds or cold tunnels. The formed gelling mixture is preferably cooledto a temperature of below 20° C., more preferably less than 15° C. tocomplete gel formation. One method of cooling is to contact the gellingmixture with a “cold table” surface as is widely used in the manufactureof a “processed” cheese.

[0111] Alternatively, the hot coagulated gelled mixture may be directlypackaged and gel formation completed upon cooling either using a methoddescribed above, or by simply leaving to cool in storage.

[0112] Steps (viii) and (ix)

[0113] The moulding and packaging steps (viii) and (ix) respectively areoptional and may be carried out by any suitable methods known in theart. However, in a preferred embodiment the gelled dairy product iscooled, formed/moulded and packaged into individual portions by suitabletechniques known in the art to provide a product which is ready forimmediate distribution to the market place.

[0114] In addition, further process steps may be applied to the presentprocess to produce a desired final food product. For example, theemulsion of step (iii) may be aerated or whipped if it is desired toproduce an aerated or whipped product such as a mousse.

[0115] The present invention further provides a stable dairy based foodproduct comprising gelled protein wherein said product does not containany emulsifying salts or non dairy derived emulsifying agents andfurther has greatly reduced active residual enzymes and/ormicroorganisms compared to similar products manufactured by traditionalprocesses.

[0116] The dairy based food product may amongst others comprise a hardor semi-soft cheese, cream cheese, yoghurt, mousse, dessert, ordressing, depending on the final moisture, fat and flavour content.Desirably, the product is a formable, stable cheese product which has acomposition similar to a traditionally made cheese as opposed to aprocessed cheese. In addition, the dairy based food product may be usedas an additive to increase the nutritional value or functionalproperties of other foods.

[0117] The present invention further provides a dairy based food productby the process of the invention, which may amongst others comprise ahard or semi-soft cheese, cream cheese, yoghurt, mousse, dessert, ordressing, depending on the type and level of modifications-used in theprocess. In addition, the dairy based food product may be used as anadditive to increase the nutritional value or functional properties ofother foods.

[0118] Any ranges mentioned in this patent specification are intended toinherently include all of the possible values within the stated range.

[0119] This invention may also be said broadly to consist in the parts,elements and features referred to or indicated in the specification ofthe application, individually or collectively, and any or allcombinations of any two or more of said parts, elements or features, andwhere specific integers are mentioned herein which have knownequivalents in the art to which this invention relates, such knownequivalents are deemed to be incorporated herein as if individually setforth.

[0120] The invention consists in the foregoing and also envisagesconstructs of which the following gives examples.

EXAMPLE 1

[0121] This example illustrates the preparation of a cheese productsimilar in characteristic to Colby cheese.

[0122] 3500 kg of fresh whole milk was standardised to 3.5% fat andpasteurised (73° C. for 16 seconds). The standardised whole milk afterheating to 50° C. was then concentrated by continuous ultrafiltration(Koch HFK 131 spiral wound membranes from Koch Membrane Systems,Wilmington, Mass., USA) using a concentration factor of approximately4.2 kg feed/kg retentate. This gave a resultant UF retentate yield of830 kg, with composition of 29.2% total solids.

[0123] The retentate was cooled to 4° C. and diluted with 4° C. water togive a retentate refractive index of 12° Brix, and the pH reduced to 5.8by the careful addition and mixing of 3% w/w lactic acid.

[0124] This acidified retentate was then heated to 50° C. anddiafiltered. Water was continuously added to maintain the refractiveindex at 12° Brix, and the pH of the retentate was modified by additionof 3% w/w lactic acid to maintain a pH of no more than 5.9.Diafiltration was continued until 35% of the total calcium in the milkhad been removed.

[0125] After diafiltration, 425 litres of this retentate were adjustedto a pH of 6.4 using 5% w/w NaOH, then batch concentrated byultrafiltration at 50° C. (Koch HFK 131 membranes), to a final retentateof 33.1% total solids, 15.1% total protein, 12.7% milk fat, 1.1% totalash, and lactose of 1.1%.

[0126] A portion, 20 kg, of the retentate was cooled to 4° C. and heldfor later use, (Ingredient A). The remainder, 405 kg, was evaporated ina two-effect falling film evaporator at a maximum product temperature of60° C., and then spray dried (Anhydro compact-style nozzle drier withintegral fluid bed, APV Nordic Anhydro, Soborg-Copenhagen, Denmark) withinlet air temperature 180° C., main chamber exit air temperature 80° C.,product feed pressure 110-140 bar, and integrated static fluid bed airtemperature 75° C. The result was a whole milk protein concentratepowder (WMPC), (Ingredient B), 97.6% total solids, 45.1% total protein,37.5% fat, 3;13% total ash, 3.31% lactose, and reduction of the calciumto protein ratio of 41% as compared to the original milk.

[0127] Fresh cream was pasteurized and separated to a high fat content,of 75% milk fat and held at 50° C. until use (Ingredient C).

[0128] A twin screw lay-down cooker (Blentech CC45, BlentechCorporation, Rohnert Park, Calif. 94927, USA) was pre-warmed to 40° C.then 3.4 kg of Ingredient A, at 4° C., 2.1 kg of Ingredient C, at 50°C., 0.17 kg salt (NaCl), and 2.1 kg warm water (70° C.) were added thenmixed over a period of one minute. Screw speed was 45 rpm.

[0129] 5.0 kg of Ingredient B, was then added over the next minute, togive a total mass of 12.77 kg whilst maintaining the temperature atapproximately 45 to 50° C. by indirect heating.

[0130] Mixing continued for a further 19 minutes. Screw speed wasunchanged at 45 rpm. At this point, the mixed material was a homogeneousemulsion.

[0131] The operating speed was then increased to 120 rpm and thetemperature slowly raised from 45° C. to 70° C. over four minutes by thedirect injection of culinary steam. During this stage of processing,heating and agitation, the emulsion started to coagulate and becamecohesive.

[0132] Hot coagulum was discharged at slow agitator speed through theend gate of the lay-down cooker into a plastic bag, sealed and formedinto a flat sheet of around 20 mm thickness on a chilled stainless steelsurface, (‘cold table’, surface temperature approximately 2° C.) andcooled for 60 minutes. This bagged product was frequently turned on thecold table and was then stored at cool-room conditions, 5° C.

[0133] The resultant final product had the form of a gelled, cheese-likeproduct of the following approximate composition: 60% total solids, 21%total protein, 36% fat, 60% fat in dry matter, 1.6% salt (NaCl), and apH of 6.2.

[0134] Visual observation and texture tests demonstrated that theproduct had colour and texture characteristics similar to that of Colbycheese.

EXAMPLE 2

[0135] This example illustrates a method for the preparation of a cheeseproduct similar in characteristic to a cheddar cheese.

[0136] Fresh whole milk was separated to give 3300 litres of skim milkof 0.08% fat. The skim milk was pasteurised (73.5° C. for 16 seconds)and cooled to 4° C. The cream removed during separation was pasteurised,cooled to 4° C. and held aside for blending back at a later stage.

[0137] The pH of the skim milk was reduced to 5.9 by the carefuladdition and mixing of 3% w/w lactic acid, and held for 105 minutes. Theslim milk was then concentrated by continuous ultrafiltration (Koch HFK131 membranes) at a temperature of 15° C., using a concentration factorof approximately 5.2 kg feed/kg retentate. Continuous diafiltrationwater was added into the plant at a ratio of about 1 part of water per16 parts of skim milk. This gave a resultant UF retentate yield of 630litres, with a composition of 20% total solids, 15.8% milk protein, andremoval of approximately 40% of the total calcium in the milk.

[0138] A portion of the retentate was cooled to 4° C. and held for lateruse (Ingredient A). The remainder was blended with cream of 40% fatlevel (from the original whole milk separation) at a required weightratio to give a retentate/cream mix with fat in the dry matter of 25.3%.This blend was then spray dried (Anhydro compact-style nozzle drier withintegral fluid bed) with inlet air temperature 180° C., main chamberexit air temperature 72° C., product feed pressure 90 bar, andintegrated static fluid bed air temperature 75° C. The result was a skimmilk protein concentrate powder (SMPC), (Ingredient B), 98% totalsolids, 57.3% protein, and reduction of the calcium to protein ratio of36% as compared to the original skim milk.

[0139] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0140] In addition, pasteurised skim milk was processed as follows: 1800litres of skim milk was pasteurised, cooled to 8° C., and then calfrennet extract was added at a ratio of 1:18,000. The skim milk was heldunagitated for approximately 14 hours. The pH was then reduced to 5.4 bythe in-line injection of food grade acid, heated to 45° C. and held forfive minutes, during which time a curd precipitate formed. The curd wasseparated from the whey by an inclined dewheying screen. The curd wasthen washed in acidified water of approximately 32° C. and pH 2.6, usinga ratio of 0.5 litres of wash water for each litre of original skimmilk. The curd/water mixture was then dewatered by pumping to ahorizontal solid bowl decanter centrifuge (Sharples J83P-2000 CV,Penwalt Corporation, Warminister, Pa., USA), to give a curd with amoisture of approximately 53%. This curd was milled to achieve aparticle size reduction by processing through an ‘Urschel Comitrol’mill. The milled curd was then dried in a ring-drier (Barr and Murphy,Barr-Rosin Ltd, Maidenhead, Berkshire, UK) with an inlet air temperatureof 180° C. and exit air temperature of 70° C. The dried curd was siftedthrough a 180 μm aperture screen to remove oversize material. Thissifted curd product (Ingredient D) had a composition of 6.8% moisture;0.5% fat, 87.4% protein, 1.2% lactose, a calcium level of 400 mmol kg,and a pH of 6.0.

[0141] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C., then 4.5 kg of Ingredient C, at 50° C., 3.8 kg of Ingredient Aat 4° C., 5.2 kg of Ingredient B, 0.25 kg of Ingredient D and 0.25 kgsalt NaCl) were added then mixed over a period of two minutes whileindirect heat was applied, to achieve a temperature of 50° C. Screwspeed was 120 rpm.

[0142] 0.45 kg of a natural dairy flavour (Maverik JLS 2040, MaverikFlavors and Ingredients, LLC, Saukville, Wis., USA) and 0.02 kg of 80%w/w lactic acid were then added. Mixing continued for a further 14minutes with the screw speed unchanged at 120 rpm. At this point, themixed material was a homogeneous emulsion.

[0143] The temperature was raised from 50° C. to 70° C. over two minutesby the direct injection of culinary steam. During this stage ofprocessing, heating and agitation, the emulsion started to coagulate andbecame cohesive.

[0144] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0145] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 68.0% total solids, 26.4% totalprotein, 32.0% fat, 3.8% total ash, 1.9% salt (NaCl), 5.8% lactose, anda pH of 5.49.

[0146] Visual observation and texture tests demonstrated that theproduct had colour and texture characteristics similar to that ofCheddar cheese.

EXAMPLE 3

[0147] This example illustrates a method for the preparation of a cheeseproduct, similar in characteristic to Colby cheese.

[0148] Fresh whole milk was separated to give 9800 litres of skim milkof 0.08% fat. The skim milk was pasteurised (73.5° C. for 16 seconds)and cooled to 6° C. The cream removed during separation was pasteurised,cooled to 4° C. and held aside for blending back at a later stage.

[0149] The pH of the skim milk was reduced to 5.9 by the carefuladdition and mixing of 3% w/w lactic acid, and held for 80 minutes. Theskim milk was then concentrated by continuous ultrafiltration (Koch HFK131 membranes) at a temperature of 15° C., using a concentration factorof approximately 4.5 kg feed/kg retentate. Continuous diafiltrationwater was added into the plant at a ratio of about 1 part of water per42 parts of skim milk. This gave a resultant UF retentate yield of 2170litres, with a composition of 18.7% total solids, 14.5% milk protein,and removal of approximately 42% of the total calcium in the milk.

[0150] Retentate was blended with cream of 40% fat level (from theoriginal whole milk separation) at a required weight ratio to give aretentate/cream mix with fat in the dry matter of 38%. This blend wasthen evaporated in a Wiegand two-effect falling film evaporator (GEAWiegand, GmbH, Einsteinstraβe 9-15, 76275 Ettlingen, Germany), with amaximum product temperature of 57° C. This gave a resultant concentrateof 43% total solids.

[0151] This concentrate was then ether evaporated in an Artisan agitatedthin film evaporator (Artisan Industries Inc, Waltham, Mass., USA) at aproduct temperature of 43° C., to give a paste with total solids levelof 48.5% (Ingredient A).

[0152] In addition, fresh whole milk was separated to give 7540 litresof skim milk of 0.08% fat. The skim milk was pasteurised (73.5° C. for16 seconds) and cooled to 4° C. The cream removed during separation waspasteurised, cooled to 4° C. and held aside for blending back at a laterstage.

[0153] The pH of the skim milk was reduced to 5.9 by the carefuladdition and mixing of 3% w/w lactic acid, and held for 90 minutes. Theskim milk was then concentrated by continuous ultrafiltration (Koch HFK131 membranes) at a temperature of 15° C., using a concentration factorof approximately 5.0 kg feed/kg retentate. Continuous diafiltrationwater was added into the plant at a ratio of about 1 part of water per46 parts of skim milk. This gave a resultant UF retentate yield of 1500litres, with a composition of 18.7% total solids, 14.2% milk protein,and removal of approximately 45% of the total calcium in the milk.

[0154] The retentate was blended with cream of 40% fat level (from theoriginal whole milk separation) at a required weight ratio to give aretentate/cream mix with fat in the dry matter of 39.6%. This blend wasthen evaporated in a Wiegand two-effect falling film evaporator, with amaximum product temperature of 57° C. This gave a resultant concentrateof 43% total solids.

[0155] This concentrate was then spray dried (Anhydro compact-stylenozzle drier with integral fluid bed) with inlet air temperature 185°C., main chamber exit air temperature 68° C., product feed pressure 95to 110 bar, and integrated static fluid bed air temperature 70° C. Theresult was a skim milk protein concentrate powder (SMPC), (IngredientB), 95.3% total solids, 43.4% protein, 39.6% fat in dry matter, andreduction of the calcium to protein ratio of 47% as compared to theoriginal skim milk.

[0156] A further ingredient was prepared by the same process as used toprepare Ingredient D in Example 2. This curd product (ingredient D) hada composition of 5.2% moisture, 0.4% fat, 88.4% protein, 1.4% lactose, acalcium level of 425 mmol/kg, and a pH of 5.9.

[0157] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C. then 10.45 kg of Ingredient A was added, and indirectly heated toa temperature of 47° C. while being stirred for five minutes. Screwspeed was 130 rpm. Screw speed was increased to 160 rpm and 3.15 kg ofIngredient B, 0.25 kg of Ingredient D, 0.25 kg of salt (NaCl), and 0.05kg of citric acid powder were added over a period of one minute. Mixingcontinued for a further six minutes at a screw speed of 160 rpm. At thispoint, the mixed material was a homogeneous emulsion.

[0158] The operating speed was then decreased to 80 rpm. The temperaturewas raised from 50° C. to 70° C. over two minutes by the directinjection of culinary steam. During this stage of processing, heatingand agitation, the emulsion started to coagulate and became cohesive.

[0159] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0160] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 60.5% total solids, 27.3% totalprotein, 23.2% fat, 3.8% total ash, 1.9% salt (NaCl), 6.2% lactose, acalcium level of 5140 mg/kg, and a pH of 5.53.

[0161] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of Colby cheese.

EXAMPLE 4

[0162] This example illustrates a method for the preparation of a cheeseproduct, similar in characteristic to Edam cheese.

[0163] A skim milk UF retentate was prepared as in the preparation ofIngredient A of Example 3. This retentate was blended with cream of 40%fat level as in Example 3, but at a required weight ratio to give aretentate/cream mix with fat in the dry matter of 41%. This blend wasthen evaporated in a Wiegand two-effect falling film evaporator, with amaximum product temperature of 57° C. This gave a resultant concentrateof 40.5% total solids.

[0164] This concentrate was then further evaporated in an Artisanagitated thin film evaporator at a product temperature of 39° C., togive a paste with total solids level of 46.1% (Ingredient A).

[0165] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0166] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C., then 8.1 kg of Ingredient A, 2.45 kg of Ingredient C, 3.1 kg ofIngredient B as described in Example 3, 0.25 kg of Ingredient D asdescribed in Example 3, 0.245 kg of salt (NaCl), and 0.03 kg of 80% w/wlactic acid were added over a period of two minutes. Screw speed was 50rpm. Mixing continued for a further 9 minutes at this screw speed. Thescrew speed was then increased to 160 rpm and mixing continued for afurther eight minutes. 0.75 kg of a natural dairy flavour (Maverik JLS2131, Maverik Flavors and Ingredients, LLC, Saukville, Wis., USA) wasthen added and stirred in over one minute while screw speed wasmaintained at 160 rpm. At this point, the mixed material was ahomogeneous emulsion.

[0167] The operating speed was then decreased to 80 rpm The temperaturewas raised from 45° C. to 70° C. over three minutes by the directinjection of culinary steam. During this stage of processing, heatingand agitation, the emulsion started to coagulate and became cohesive.

[0168] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0169] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 62.3% total solids, 23.1% totalprotein, 30.9% fat, 3.4% total ash, 1.8% salt (NaCl), 4.9% lactose, acalcium level of 4290 mg/kg, and a pH of 5.51.

[0170] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of Edam cheese.

EXAMPLE 5

[0171] This example illustrates a method for the preparation of a cheeseproduct, with a semi-hard cheese texture.

[0172] Fresh whole milk was pasteurised (73° C. for 16 seconds),separated and then fat standardised to produce 3480 litres of milk of3.8% protein, 4.75% milk fat, and 12% total solids.

[0173] The whole milk was cooled to 5° C. and then the pH of the milkwas reduced to 5.95 by the careful addition and mixing of 3% w/w lacticacid, and held for 90 minutes. The milk was then concentrated bycontinuous ultrafiltration (Koch HFK 131 membranes) at a temperature of45° C., using a concentration factor of approximately 4.2 kg feed/kgretentate. Continuous diafiltration water was added into the plant at aratio of about 1 part of water per 9 parts of whole milk. This gave aresultant UF retentate yield of 825 litres, with a composition of 31.7%total solids, 12.2% milk protein, and removal of approximately 40% ofthe total calcium in the milk.

[0174] The whole milk retentate was evaporated in a Wiegand two-effectfalling film evaporator, with a maximum product temperature of 57° C.,producing a concentrate of approximately 45% total solids.

[0175] This concentrate was then further evaporated in an Artisanagitated thin film evaporator at a product temperature of 36° C., togive a paste with total solids level of 55.7% (Ingredient A).

[0176] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0177] A further ingredient was prepared by the same process as used toprepare Ingredient D in Example 2. This curd product (Ingredient D) hada composition of 8.3% moisture, 0.6% fat, 87.9% protein, 1.1%4 lactose,a calcium level of 216 mmol kg, and a pH of 5.5.

[0178] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C., then 8.37 kg of Ingredient A, 2.07 kg of Ingredient C, and 1.95kg of a high-fat Milk Protein Concentrate powder (ALAPRO Spec 4454,NZMP, New Zealand) were added over a period of two minutes. Screw speedwas 50 rpm. Screw speed was then increased to 160 rpm. After one minute,0.225 kg of Ingredient D, 0.23 kg of salt (NaCl), and 0.05 kg of 80% w/wlactic acid were added over a further period of one minute. Mixingcontinued for a further nine minutes at a screw speed of 160 rpm. Atthis point, the mixed material was a homogeneous emulsion.

[0179] The operating speed was then decreased to 80 rpm. The temperaturewas raised from 27° C. to 70° C. over four minutes by the directinjection of culinary steam. During this stage of processing, heatingand agitation, the emulsion started to coagulate and became cohesive.

[0180] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0181] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 62.5% total solids, 20.3% totalprotein, 32.3% fat, 3.5% total ash, 1.9% salt (NaCl), 6.4% lactose, acalcium level of 4360 mg/kg, and a pH of 5.60.

[0182] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of a soft Colbycheese.

EXAMPLE 6

[0183] This example illustrates a method for the preparation of a cheeseproduct similar in characteristic to Cheddar cheese.

[0184] The following ingredients were added into a mixer bowl similar toa ‘Hobart’ type (Hobart Corporation, Troy, Ohio 45374, USA) as follows:9.2 kg of cream (40% fat) was preheated in a stainless steel containerby indirect hot water, and was then added into the mixer bowl andstirred at 40 rpm for one minute while heated to 55° C. Insulatedelectrical heat trace provided an indirect heating source on the mixerbowl. 8.8 kg of Ingredient B as described in Example 3 was added andmixed in the bowl for eight minutes. Then 0.5 kg of Ingredient D asdescribed in Example 2, and 0.28 kg of salt (NaCl) were added over oneminute. After another two minutes of mixing at 40 rpm, 0.05 kg of 80%w/w lactic acid was added. The mixing speed was increased to 60 rpm andmixing continued for a further thirteen minutes. Some of this materialwas then extracted from the bowl. After a holding time of 90 minutes,0.675 kg of warm water was added to the remaining 11.6 kg of thismixture to give a mix at 33° C. At this point, the mixed material was ahomogeneous emulsion.

[0185] This mixture was then transferred to a feed hopper attached to aMiltenz 51-SP single-screw extruder (Millbank Technology (NZ) Ltd,Panmure, Auckland, New Zealand). The product passed through asteam-jacketed extruder barrel (inner diameter 48 mm and screw outerdiameter of 45 mm) at a screw speed of 236 rpm, with a product inlettemperature of 43° C., a product outlet temperature of 83° C. and a dieoutlet of 6 mm diameter. During this stage of processing, heating andagitation, the emulsion started to coagulate and became cohesive.

[0186] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0187] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 70.7% total solids, 23.7% totalprotein, 38.3% fat, 3.3% total ash, 1.6% salt (NaCl), 5.4% lactose, anda pH of 5.52.

[0188] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of Cheddar cheese.

EXAMPLE 7

[0189] This example illustrates a method for the preparation of a cheeseproduct similar in characteristic to Edam cheese.

[0190] A twin-screw lay-down cooker (Blentech CC45) was pre-warmed to40° C. Then 6.8 kg of cream (40% fat) was added and indirectly heatedfrom 10° C. to 41° C. over a one-minute period. Screw speed during thisheating was 48 rpm. 6.8 kg of Ingredient B as described in Example 3,0.87 kg of warm water, 0.19 kg of salt, and 0.25 kg of Ingredient D asdescribed in Example 2, were added over the next two minutes, followedby 0.05 kg of 80% w/w lactic acid a minute later. Screw speed continuedat 48 rpm during these additions and for a further two minutes. At thispoint, the mixed material was a homogeneous emulsion.

[0191] The operating speed was then increased to 80 rpm. The temperaturewas raised from 41° C. to 50° C. over two minutes by the indirectheating. The emulsion was packed into a large plastic bag, and held in awarm insulated bin until further use.

[0192] The process was continued when the emulsion was transferred to amanual sausage filler. This filler was used to feed the emulsion througha microwave applicator at a rate of 6.5 kg/hr. The microwave applicatorconsisted of a short length of 100 mm×50 mm rectangular waveguide with a30 mm plastic product pipe spanning the 100 mm dimension. The emulsionwas heated in the microwave section from an inlet temperature of 50° C.to an outlet temperature of 100° C. The heated product was then passedthrough a twin-screw extruder (Clextral BC21, Clextral SA, 42702 FirminyCedex, France) operating at a screw speed of around 450 rpm, and a dieoutlet temperature of around 100° C. During these stages of microwaveheating and extruder processing, the emulsion started to coagulate andbecame cohesive.

[0193] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0194] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 66.7% total solids, 21.7% totalprotein, 36.3% fat, 3.0% total ash, 1.4% salt (NaCl), and 5.7% lactose,and a pH of 5.56.

[0195] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of Edam cheese.

EXAMPLE 8

[0196] This example illustrates a method for the preparation of a cheeseproduct, similar in characteristic to Colby cheese.

[0197] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0198] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C., then 6.5 kg of Ingredient B as described in Example 3, 3.4 kg ofIngredient C, 0.24 kg of salt (NaCl), 0.25 kg of Ingredient D asdescribed in Example 2, 0.75 kg of a natural dairy flavour (Maverik JLS2131, Maverik Flavors and Ingredients, LLC, Saukville, Wis., USA), and2.9 kg of warm water (70° C.) were added over a period of two minutes.Screw speed was 50 rpm. Mixing continued for a further two minutes atthis screw speed. The speed was then increased to 160 rpm and mixingcontinued for a further ten minutes. At this point, the mixed materialwas a homogeneous emulsion.

[0199] The screw speed was then decreased to 80 rpm and direct steaminjection was commenced so that the combined mass heated from approx 45°C. to 70° C. over two minutes. During this stage of processing, heatingand agitation, the emulsion started to coagulate and became cohesive.

[0200] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0201] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 0.67.6% total solids, 22.4% totalprotein, 36.6% fat, 3.5% total ash, 1.9% salt NaCl), and 5.1% lactose,and a pH of 5.36.

[0202] In a sensory evaluation a week later, the sample was described asa clean, creamy full-flavoured product, similar to mild Cheddar. Texturetests demonstrated that the product had texture characteristics similarto that of Colby cheese.

EXAMPLE 9

[0203] This example illustrates a method for the preparation of a cheeseproduct similar in characteristic to a Cheddar cheese.

[0204] A skim milk UF concentrate was prepared by ultrafiltration andfalling film evaporation as in the preparation of Ingredient A ofExample 3. This concentrate was then spray dried (Anhydro compact-stylenozzle drier with integral fluid bed) with inlet air temperature 185°C., main chamber exit air temperature 70° C., product feed pressure 125bar, and integrated static fluid bed air temperature 71° C. The resultwas a milk protein concentrate powder (MPC), (Ingredient B), 98.5% totalsolids, 44.2% protein, 41.4% fat, 3.5% total ash, 11.6% lactose, andreduction of the calcium to protein ratio of 56% as compared to theoriginal skim milk.

[0205] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0206] A twin screw lay-down cooker (Blentech CC45), was pre-warmed to40° C., then 2.8 kg of Ingredient C, 3.68 kg of warm water and 7.28 kgof Ingredient B were added and then indirectly heated over two minutesto give a mixture temperature of 49° C. Screw speed was 50 rpm over thisaddition and heating time. 0.255 kg of salt (NaCl) and 0.06 kg of 80%w/w lactic acid were then added over the next minute while screw speedremained at 50 rpm. The screw speed was then increased to 160 rpm andmixing continued for eight minutes. 0.04 kg of pure locust bean gum(Grinsted LBG 066, Danisco Ingredients, Brabrand, Denmark) was thenadded, and mixing continued at a screw speed of 160 rpm for a furthertwo minutes. At this point, the mixed material was a homogeneousemulsion.

[0207] The screw speed was then decreased to 80 rpm and direct steaminjection was commenced so that the combined mass heated from 50° C. to70° C. over two minutes. During this stage of processing, heating andagitation, the emulsion started to coagulate and became cohesive.

[0208] Samples of the hot coagulum were packed into 500-gram tubs,stored at cool-room conditions, 5° C. overnight, and then vacuum packed.

[0209] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 67.6% total solids, 22.3% totalprotein, 36.0% fat, 3.6% total ash, 2.0% salt (NaCl), and 6.3% lactose,and a pH of 5.61.

[0210] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of a Cheddar cheesebut with a more elastic, fibrous structure.

EXAMPLE 10

[0211] This example illustrates a method for the preparation of acheese-like product, with a semi-hard cheese texture.

[0212] A deodorised, partially hydrogenated soya bean oil (HSBO) ofspecified solid fat content profile (10° C.: 58-65%; 20° C.: 38-34%; 30°C.: 5-9%) and iodine value (75-81) (supplied by Bakels Edible Oils Ltd,Mt Maunganui, New Zealand) was melted.

[0213] A twin screw lay-down cooker (Blentech CC45), was pre-warned to40° C., then 4.53 kg of warm water, 2.45 kg of the melted HSBO, and 6.6kg of Ingredient B as used in Example 9, were added and indirectlyheated over one minute to give a mixture temperature of 45° C. Screwspeed was 50 rpm over this addition and heating, time. 0.255 kg of salt(NaCl), 0.25 kg of Ingredient D as described in Example 3, and 0.06 kgof 80% w/w lactic acid were then added over the next minute while screwspeed remained at 50 rpm. The screw speed was then increased to 160 rpmfor a period of five minutes, and then to 200 rpm for nine minutes. Atthis point, the mixed material was a homogeneous emulsion.

[0214] The screw speed was then decreased to 80 rpm and direct steaminjection was commenced so that the combined mass heated from 45° C. to72° C. over two minutes. During this stage of processing, heating andagitation, the emulsion started to coagulate and became cohesive.

[0215] Samples of the hot coagulum were packed into 500-gram tubs,stored at cool-room conditions, 5° C. overnight, and then vacuum packed.

[0216] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 65.4% total solids, 21.3% totalprotein, 35.9% fat, 3.4% total ash, 1.9% salt NaCl), 4.8% lactose, acalcium level of 4060 mg/kg, and a pH of 5.59.

[0217] Visual observation and texture tests demonstrated that theproduct had smooth texture characteristics similar to that of a softColby cheese.

EXAMPLE 11

[0218] This example illustrates a method for the preparation of acheese-like product, with a semi-hard cheese texture.

[0219] A twin screw lay-down cooker (Blentech CC10), was pre-warmed to40° C., then 1.7 kg of warm water (70° C.) and 1.75 kg of meltedanhydrous milkfat (AMF) were added and mixed over a period of threeminutes. The mix temperature was 52° C. Screw speed was 80 rpm. A dry,pre-mixed combination of 0.75 kg of SUPRO EX33 Soy Protein Isolate(Protein Technologies International, Pryor, Okla., USA) and 0.75 kg ofInstant Skim milk powder (Spec 6820, NZMP, Wellington New Zealand) wasthen added and mixed in over a period of one minute. Screw speed wasthen increased to 160 rpm. 0.24 kg of salt (NaCl) and 0.05 kg of 80% w/wlactic acid were then added and mixing of this material continued for afurther 15 minutes. At this point, the mixed material was a homogeneousemulsion.

[0220] The operating speed was then decreased to 80 rpm and after oneminute, the temperature was raised from 48° C. to 71° C. over twominutes by the direct injection of culinary steam. During this stage ofprocessing, heating and agitation, the emulsion started to coagulate andbecame cohesive.

[0221] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight, and were thenvacuum packed.

[0222] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 63.5% total solids, 18.1% totalprotein, 34.1% fat, 3.3% total ash, 1.9% salt (NaCl), 8.0% lactose, acalcium level of 1830 mg/kg, and a pH of 5.38.

[0223] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of a soft Cheddarcheese.

EXAMPLE 12

[0224] This example illustrates a method for the preparation of a cheesespread-like product.

[0225] A skim milk UF concentrate was prepared by ultrafiltration andfailing film evaporation as in the preparation of Ingredient A ofExample 3.

[0226] This concentrate was then further evaporated in an Artisanagitated thin film evaporator at a product temperature of 43° C., togive a paste with total solids of 45.5% (Ingredient A).

[0227] Ingredients were added into a Stephan upright cooker (model UMMISK 25 GNI, A. Stephan und Söhne GmbH & Co., Hameln, Germany) (nominalbatch capacity 25 kg) as follows: 10.0 kg of Ingredient A and 0.1 kg ofsalt (NaCl) were added and mixed for six minutes at a scraper stirrerspeed of 60 rpm and knife speed of 1500 rpm. Indirect heating was usedduring this time to increase the temperature from 28° C. to 42° C.

[0228] The knife speed was then increased to 3000 rpm and direct steaminjection was commenced, so that the mixture temperature increased from42° C. to 73° C. over three minutes. During this stage of processing,heating and agitation, the emulsion started to coagulate and becamecohesive.

[0229] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight, and then vacuumpacked

[0230] The resultant final product had the following composition: 42.3%total solids, 17.2% total protein, 17.0% fat, 1.4% total ash, 1.1% salt(NaCl), 6.7% lactose, and a calcium level of 3140 mg/kg.

[0231] Visual observation demonstrated that the product had texturecharacteristics similar to that of a cheese spread.

EXAMPLE 13

[0232] This example illustrates a method for the preparation an aerated,mousse-like product.

[0233] Ingredients were added into a Stephan upright cooker (Model UMMISK 25 GNI) as follows: 0.7 kg of Ingredient B as described in Example9, 16.8 kg of fresh 42% fat cream (4° C.) and 0.34 kg of salt (NaCl)were added and mixed for five minutes at a scraper speed of 60 rpm.Indirect heating was used during this time to increase the temperaturefrom 18° C. to 48° C. 0.33 kg of Ingredient D as described in Example 5was then added and mixing continued for three minutes at a scraper speedof 60 rpm and a knife speed of 3000 rpm. 0.08 kg of 80% w/w lactic acidwas then added. Mixing continued for a further two minutes at a scraperspeed of 60 rpm and a knife speed of 3000 rpm, then a five kilogram subsample was taken and set aside for comparison with the finished product.Mixing of the remaining mixture was then continued for another nineminutes at a scraper speed of 60 rpm and a knife speed of 3000 rpm, andanother sub sample was then taken.

[0234] After a further four minutes of mixing at the above conditions,direct steam injection was then commenced, so that the mixturetemperature increased from 48° C. to 70° C. over two minutes. Mixingcontinued during this time at a scraper speed of 60 rpm and a knifespeed of 3000 rpm.

[0235] Samples of the hot, mousse-like coagulum and of the five-kilogramsub sample were packed into 500-gram tubs and then stored at cool-roomconditions, 5° C. overnight, and then vacuum packed.

[0236] The resultant final product had the following composition: 48.8%total solids, 4.8% total protein, 38.9% fat, 2.3% total ash, 1.8% salt(NaCl), 2.8% lactose, a calcium level of 920 mg/kg, and a final pH of5.11.

[0237] The resultant product was described as a soft, but structured,smooth, aerated gel, which did not pour. In contrast, the cooled subsample that had not been heated to 70° C. was a still flowable liquid.

EXAMPLE 14

[0238] This example illustrates a method for the preparation of ayoghurt-like product.

[0239] 0.7 kg of Ingredient B as described in Example 9, 3.0 kg ofInstant Skim milk powder (Spec 6820, NZMP), and 0.1 kg of pure locustbean gum (Grinsted LBG 066) were mixed in a dry container to create apowder premix.

[0240] Ingredients were then added into a Stephan upright cooker (ModelUMM ISK 25 GNI) as follows: 8.75 kg of warm water (70° C.) and then thepowder premix were added. A ten-second period of mixing at a scraperstirrer speed of 60 rpm and a knife speed of 1500 rpm was followed byfive minutes of mixing at a scraper speed of 60 rpm. Indirect heatingwas then used to heat the mixture from 48° C. to 80° C. over atwo-minute period while mixing at a scraper speed of 60 rpm and a knifespeed of 1500 rpm. The mixture then held at 80° C. for a further twominutes while stirring continued at scraper speed of 60 rpm. Indirectcooling was then applied, to lower the mixture temperature to 35° C.over a fifteen-minute period. A blend of 0.96 kg of 20% w/w lactic acidand 0.24 kg of 20% w/w acetic acid was added very slowly to the mixtureas three separate part doses, while nixing was stopped. Five seconds ofmixing at a scraper speed of 60 rpm was allowed after the addition ofeach part dose to stir the acid in. This was followed by a final 10minutes of mixing at a scraper speed of 60 rpm.

[0241] The warm, yoghurt-like mass was poured into 250-gram, clear,plastic screw-top containers and cooled overnight at cool-roomconditions of 5° C.

[0242] The resultant final product had the following composition: 24.1%total solids, 8.6% total protein, 1.1% fat, 1.7% total ash, 0.3% salt(NaCl), 12.7% lactose, a calcium level of 2900 mg/kg, and a final pH of4.4.

[0243] The resultant product texture was described as a smooth, creamy,slightly aerated, yoghurt-like gel, similar to fromage frais.

EXAMPLE 15

[0244] This example illustrates a method for the preparation of a cheeseproduct, similar in characteristic to Colby cheese.

[0245] 79.2 kg of Ingredient B as described in example 9 wasreconstituted into 180.8 kg water of 50° C. in a high shear mixingvessel. Agitation was continued for one hour after powder addition. Thisgave a resultant concentrate of 30% total solids.

[0246] This concentrate was then further evaporated in an Artisanagitated thin film evaporator at a product temperature of up to 60° C.,to give a paste with a refractive index of around 54° Brix (IngredientA).

[0247] Fresh high fat cream (Ingredient C) was produced as described inExample 1.

[0248] 2.8 kg of Ingredient A, 0.2 kg of Ingredient C, 0.046 kg of salt(NaCl), and 0.015 kg of 80% w/w lactic acid were added over a period offour minute into a twin screw lay-down cooker (Blentech CC10). Screwspeed was 55 rpm. This mix was indirectly steam heated from 19 to 49° C.over a period of 5 minutes. At this point, the mixed material was ahomogeneous emulsion.

[0249] After holding for another 2 minutes at 49° C. and mixing at 55rpm, the temperature was raised from 49° C. to 70° C. over ten minutesby indirect steam heating. During this stage of processing, heating andagitation, the emulsion started to coagulate and became cohesive.

[0250] Samples of the hot coagulum were packed into 500-gram tubs andthen stored at cool-room conditions, 5° C. overnight.

[0251] The resultant final product had the form of a gelled, cheese-likeproduct of the following composition: 63.7% total solids, 24.5% totalprotein (calculated), 28.8% fat (calculated), total ash 4.0%(calculated), 2.0% salt (NaCl) (calculated), 6.5% lactose (calculated),a calcium level of 3560 mg/kg (calculated), and a pH of 5.41.

[0252] Visual observation and texture tests demonstrated that theproduct had texture characteristics similar to that of Colby cheese.

INDUSTRIAL APPLICATION

[0253] Particularly, although by no means exclusively, the inventionrelates to a process for making a cheese product wherein there aregreatly reduced residual active enzymes or microorganisms, and noemulsifying salts or non dairy based emulsifying agents in the finishedproduct. This process is particularly advantageous over prior artprocesses as it can produce consistent cheese products having similarorganoleptic properties to traditionally made cheeses but which areproduced much more quickly, as such cheese products require nomaturation time. In addition, as the rate of spoilage due to enzymaticor microbial action is significantly reduced, these products have anincreased shelf life as compared to traditionally made cheeses. They arealso considerably less material, labour and cost intensive and more costeffective to produce where the production, packaging and storage processmay be largely automated and simplified.

[0254] It will be appreciated that it is not intended to limit theinvention to the above examples only, many variations, such as mightreadily occur to a person skilled in the art being possible withoutdeparting from the scope of the appended claims.

1. A process for making a fat-containing stable dairy based food productcomprising the steps: (i) providing a first milk protein basedcomposition; (ii) optionally dehydrating said first milk protein basedcomposition to increase total solids to 15 to 99 wt % if required; (iii)combining the product from steps (i) or (ii) with at least one additive,other than an emulsifying salt or non dairy derived emulsifying agents,selected from the group comprising, a flavour enhancer, a textureenhancer, a nutritional supplement, a fat source, a carbohydrate source,condiments, a second milk protein based composition, a non-dairy proteinsource, and any other dairy derived product or GRAS ingredient, andagitating to create a stable emulsion; (iv) heating the emulsion of step(ill) to a temperature above 50° C. for up to 60 minutes, to initiatecoagulation and gel formation; (v) optionally further agitating eitherconcurrently with heating step (iv) or subsequent thereto, to assist incoagulation and impart the desired texture formation; (vi) optionallyforming the mixture of step (iv) or (v) into a suitable shape; and (vii)cooling the mixture of step (iv) or (v), or the formed mixture of step,(vi), to complete gel formation and to produce a final food product;wherein the first and/or second milk protein based composition ismodified to alter one or more properties selected from flavour, texture,nutritional composition and functionality of the final food product; andwherein said first and/or second milk protein based compositioncomprises a milk or milk product selected from the group consisting ofpasteurized or unpasteurized whole milk, skim milk, reduced fat milk,fat enhanced milk, milk ultrafiltration retentates, milk concentrates,powdered whole, reduced fat or skim milk, reconstituted whole, reducedfat or skim milk powder or any combination thereof, wherein said milk ormilk product is sourced from any milk producing animal or analogue milk;with the proviso that when the first milk protein based composition ofstep (i) or (ii) is a milk ultrafiltration retentate, the second milkprotein based composition or non-dairy protein source added in step(iii) is not a protein concentrate or isolate when the process is usedto make cheese.
 2. A process as claimed in claim 1, further comprisingthe optional steps of: (viii) moulding/forming the cooled food productinto a suitable shape; and/or (ix) packing the final food product into asuitable package.
 3. A process as claimed in claim 1, wherein at leastone of the said first and/or second milk protein based compositions ismodified in at least one step of the process of claim 1 by one or morefo the group consisting of pH adjustment, mineral level adjustment,protein level adjustment, fat level adjustment, lactose leveladjustment, moisture level adjustment, NaCl/KCl or enzyme addition,temperature treatment and shearing processes.
 4. A process as claimed inclaim 3, wherein said at least one modification increases thehydrophobicity of said milk protein.
 5. A process as claimed in claim 4wherein the food product, comprises both a first and second milk proteinbased composition.
 6. A process as claimed in claim 1, wherein saidfirst milk protein based composition is dehydrated to give increasedtotal solids to less than 75% if required.
 7. A process as claimed inclaim 1, wherein the fat content of the first and/or second milk proteinbased composition is adjusted to between 0.05 and 7 wt % and the proteincontent adjusted to between 2 and 6 wt %.
 8. A process as claimed inclaim 7, wherein the fat content is adjusted to between 0.05 and 5 wt %and the protein content adjusted to between 2.5 and 4 wt %.
 9. A processas claimed in claim 1, wherein combining step (iii) is carried out in adevice capable of mechanical shear sufficient to produce a stableemulsion on mixing without having to add emulsifying salts.
 10. Aprocess as claimed in claim 1, wherein the flavour enhancer is selectedfrom the group consisting of NaCl, KCl, food grade acids includinglactic acid, citric acid, acetic acid, lactone and the like, lactose,fat, and flavours including enzyme modified cheeses.
 11. A process asclaimed in claim 1, wherein the texture enhancer is selected from thegroup consisting of water, food grade acid, lactose, fats, gums,starches, carbohydrates, sources of monovalent and divalent cations suchas CaCl₂, NaCl and KCl.
 12. A process as claimed in claim 1, wherein pHmodification is effected by addition of at least one acidulant.
 13. Aprocess as claimed in claim 12, wherein said acidulant is selected froma food grade acid and lactone.
 14. A process as claimed in claim 1,wherein the nutritional supplement is selected from the group consistingof vitamins, minerals, and carbohydrates.
 15. A process as claimed inclaim 1, wherein the second milk protein based composition is selectedfrom the group comprising: (a) whole milk, reduced fat milk, skim milkor reconstituted whole milk, reduced fat milk or skim milk having 0.05to 7% fat and 2 to 6% protein; and/or (b) a milk of group (a) which hasbeen dehydrated to increase total solids to 15 to 98%; and/or (c) a milkof group (a) and/or group (b) which has been modified to produce adesired property in the final food product.
 16. A process as claimed inclaim 15, wherein the fat and protein content of the milk protein basedcomposition of group (a) comprises 0.05 to 5 wt % fat and 2.5 to 4 wt %protein.
 17. A process as claimed in claim 15, wherein the first and/orsecond milk protein based composition is modified either before or aftersaid composition is dehydrated.
 18. A process as claimed in claim 1,wherein the heating step (iv) is carried out in a suitable device bydirect or indirect methods selected from the group consisting of steaminjection, microwave energy, indirect steam or other heating fluids,indirect electrical heating, radio frequency, ohmic heating and thelike, to a suitable temperature above 50° C.
 19. A process as claimed inclaim 18, wherein the heating step (iv) is carried out at a temperatureof up to 120° C.
 20. A process as claimed in claim 1, wherein heatingstep (iv) is carried out in the same device as the combining andemulsification step (iii), when heating takes place whilst the emulsionis being continuously agitated at a temperature range of between 50 to120° C. for up to 60 minutes to initiate coagulation and gel formation.21. A process as claimed in claim 1, wherein further agitation step (v)is carried out concurrently with heating step (iv).
 22. A process asclaimed in claim 1, wherein further agitating step (v) is carried outsubsequent to heating step (iv).
 23. A process as claimed in claim 20,wherein heating takes place at 60 to 90° C. for up to 60 minutes.
 24. Aprocess as claimed in claim 20, wherein heating takes place at 65 to 75°C. for up to 60 minutes.
 25. A process as claimed in claim 20, whereinheating takes place at a temperature range of between 50 and 120° C. forup to 10 minutes.
 26. A process as claimed in claim 20, wherein heatingtakes place at a temperature range of between 50 and 120° C. for up to 5minutes.
 27. A process as claimed in claim 1, wherein cooling step (vii)is carried out at a temperature of less than 20° C.
 28. A process asclaimed in claim 1, wherein one or more further process step are appliedto produce a desired final food product.
 29. A process as claimed inclaim 28, wherein the coagulating and gelling mixture of step (iii) isaerated or whipped to produce an aerated or whipped mousse-like product.30. A stable dairy based food product comprising gelled protein whereinsaid product does not contain any emulsifying salts or non dairy derivedemulsifying agents made by the process of claim
 1. 31. A dairy basedfood product as claimed in claim 30, selected from the group consistingof hard or semi-soft cheese, cream cheese, yoghurt, mousse, dessert, anddressing.
 32. A dairy based food product as claimed in claim 31,comprising a formable, stable cheese product which has a compositionsimilar to a traditionally made cheese compared to a processed cheese.33. A dairy based food product as claimed in claim 30, for use as anadditive to increase the nutritional value or functional properties ofother foods.